Stable emulsion of viscous crude hydrocarbon in aqueous buffer solution and method for forming and transporting same

Abstract: The method for forming a stable emulsion of a viscous crude hydrocarbon in an aqueous buffer solution, includes the steps of: providing a viscous crude hydrocarbon containing an inactive natural surfactant and having a salt content by weight of less than or equal to about 1.0% and having a total acid number of greater than or equal to about 1, preferably greater than or equal to about 2.5; forming a solution of a buffer additive in an aqueous solution to provide a basic aqueous buffer solution, the buffer additive being operative to extract and activate the inactive natural surfactant from the viscous crude hydrocarbon; and mixing the viscous crude hydrocarbon with the aqueous buffer solution at a rate sufficient to provide an emulsion of the viscous crude hydrocarbon in the aqueous buffer solution, whereby the buffer additive extracts the inactive natural surfactant from the viscous crude hydrocarbon and activates the inactive natural surfactant so as to stabilize the emulsion. The inactive natural surfactants are preferably carboxylic acids. The buffer additive is preferably selected from the group consisting of (a) sodium hydroxide in combination with sodium bicarbonate and (b) sodium silicate. A method for transporting the emulsion is also disclosed.

Description: BACKGROUND OF THE INVENTION The invention relates to an emulsion and a method for forming an emulsion of a viscous crude hydrocarbon in an aqueous buffer solution. Large reserves of crude hydrocarbons exist which, in their natural state, are very viscous. These hydrocarbons are capable of being processed into useful end products. However, the viscous nature of such viscous crude hydrocarbons makes it difficult to transport the hydrocarbons in conventional pipelines to stations where the viscous crude hydrocarbons can be treated. Typical viscous crude hydrocarbons may be characterized by the following chemical and physical properties: C wt. % of 78.2 to 85.5; H wt. % of 9.0 to 10.8; 0 wt. % of 0.26 to 1.1; N wt. % of 0.50 to 0.70; S wt. % of 2.00 to 4.50; Ash wt. % of 0.05 to 0.33; Vanadium, ppm of 50 to 1,000; Nickel, ppm of 20 to 500; Iron, ppm of 5 to 100; Sodium, ppm of 10 to 500; Gravity, API of 1.0 to 16.0; Viscosity (cST), 122°F. of 100 to 5,000,000; Viscosity (cST), 210°F. of 10 to 16,000; LHV (BTU/LB) of 15,000 to 19,000; and Asphaltenes, wt. % of 5.0 to 25.0. From a consideration of the above, particularly the viscosity, the difficulties in transporting a material in conventional pipelines can be appreciated. One solution to the problem of transporting viscous crude hydrocarbons has been to form emulsions of the hydrocarbon in water. Such emulsions exhibit greatly reduced viscosity which, of course, facilitates the transport of same. Unfortunately, such emulsions require emulsifiers to be stable, and commercial emulsifiers conventionally used in forming such an amulsion are expensive. The added cost of the commercial surfactant naturally makes the option of forming emulsions to transport viscous crude hydrocarbons less attractive. It is desirable to provide an emulsion of the viscous crude hydrocarbon in water which does not require commercial surfactants/emulsifiers for stability. Such an emulsion would provide an economical method for transporting the viscous crude hydrocarbon and, therefore, a more economical method for processing the viscous crude hydrocarbon into useful end products. In view of the above it is referred to US-A 4,487,262 which relates to a method of recovery of heavy oil from a subterranean silica-containing oil-containing formation. According to said method a hot aqueous solution containing sodium hydroxide and sodium bicarbonate is injected into the silica-containing oil-containing formation, which reacts with the silica to form metasilicate and carbon dioxide by the reaction of silica and sodium bicarbonate and to provide thermal energy by the reaction of silica and sodium hydroxide for decreasing the viscosity of the subterranean oil (see column 2, lines 4-13). More in particular the reactions with silica indicated above can be illustrated by the following equations: 2 NaHCO 3 + SiO 2 → Na 2 SiO 3 + H 2 O + 2 CO 2 ΔH 25° C= +3.7 Kcals/mole of NaHCO 3 2 NaOH + SiO 2 → Na 2 SiO 3 + H 2 O ΔH 25° C= -12.3 KCals/mole of NaOH (see column 2, lines 47-54). On account of the above reactions with silica: (1) the released CO 2 dissolves into the subterranean heavy oil present in the formation reducing its viscosity (column 2, lines 59-61); (2) the produced metasilicate lowers the interfacial tension between the oil and the formation thereby enhancing the recovery of the oil (column 2, lines 61-63) and (3) the hot thermal energy - obtained by maintaining a molar ratio of sodium bicarbonate to sodium hydroxide not greater than 3.3:1 - results in additional decrease of the viscosity of the in place oil (column 2, lines 8-9). Summerising it is stated that US-A 4,487,262 relates to a method for the recovery of heavy oil from subterranean silica- and oil-containing formation encompassing the presence of silica as a reagent resulting in both (1) the release of CO 2 , (2) the formation of metasilicate and (3) the release of thermal energy. Further is pointed at US-A 4,343,323 which relates to a pipeline transportation of heavy crude oil which comprises emulsifying the crude oil as an oil-in-water emulsion by using a sodium hydroxide solution, which solution (1) has been deaerated and (2) has a pH of at least 11, preferably at least 12. In view of the above, it is the principal object of the present invention to provide a transportable stable emulsion of a viscous crude hydrocarbon in water which does not require commercial emulsifiers for stability. It is a further object of the invention to provide such an emulsion which is easily broken once it is transported to the desired destination. It is a still further object of the invention to provide such an emulsion having two distinct droplet size populations, and, therefore, improved vicosity characteristics. It is another object of the invention to provide a method for forming such an emulsion. Other objects and advantages will appear hereinbelow. SUMMARY OF THE INVENTION The invention relates to a stable emulsion of a viscous crude hydrocarbon in an aqueous buffer solution, as well as a method for forming such an emulsion without using commercial emulsifiers for stability. According to the invention, the stable emulsion is formed by a method including the steps of: providing a viscous crude hydrocarbon containing an inactive natural surfactant and having a salt content by weight of less than or equal to about 1.0% with respect to the emulsion continuous phase and having a total acid number of greater than or equal to about 1, preferably greater than or equal to about 2.5; forming a solution of a buffer additive in an aqueous solution to provide a basic aqueous buffer solution, the buffer additive being operative to extract and activate the inactive natural surfactant from the viscous crude hydrocarbon and selected from the group consisting of (a) sodium hydroxide with sodium bicarbonate and (b) sodium silicate; and mixing the viscous crude hydrocarbon with the aqueous buffer solution at a rate sufficient to provide an emulsion of the viscous crude hydrocarbon in the aqueous buffer solution, whereby the buffer additive extracts the inactive natural surfactant from the viscous crude hydrocarbon and activates the inactive natural surfactant so as to stabilize the emulsion. The buffer additive may be added at a concentration of 8,000 ppm or more so as to provide a bimodal emulsion having improved viscosity characteristics. BRIEF DESCRIPTION OF THE DRAWINGS A detailed description of preferred embodiments of the invention follows, with reference to the accompanying drawings, wherein: Figs. 1 and 2 are graphs showing the droplet size distribution of emulsion formed according to the invention; Figs. 3 and 4 are graphs showing results of dynamic stability tests on an emulsion formed according to the invention; and Figs. 5 and 6 are graphs showing results of static stability tests on an emulsion formed according to the invention. DETAILED DESCRIPTION The invention relates to a stable emulsion of a viscous crude hydrocarbon in a basic aqueous buffer solution which is prepared without commercial surfactants. Viscous crude hydrocarbons are difficult to transport in conventional pipelines due to the high viscosity of the hydrocarbon. This difficulty has been addressed by the formation of hydrocarbon-in-water emulsions wherein commercial emulsifiers are used to stabilize the emulsion. Emulsions such as this have greatly reduced viscosity as compared to the original hydrocarbon, and are therefore easily transported through pipelines. Conventionally formed emulsions, however, as set forth above, require costly commercial emulsifiers for stability. According to the invention, viscous crude hydrocarbons are emulsified for transport without using commercial emulsifiers. Rather, the emulsions are formed by activating materials naturally contained in the viscous crude hydrocarbons. These materials are referred to herein as inactive surfactants which, when activated, are natural surfactants. The term viscous crude hydrocarbon refers generally to any viscous crude oil or bitumen which, when produced, is too viscous for practical pipeline flow. A typical viscous crude hydrocarbon may be characterized as follows: C wt. % of 78.2 to 85.5; H wt. % of 9.0 to 10.8; 0 wt. % of 0.26 to 1.1; N wt. % of 0.50 to 0.70; S wt. % of 2.00 to 4.50; Ash wt. % of 0.05 to 0.33; Vanadium, ppm of 50 to 1,000; Nickel, ppm of 20 to 500; Iron, ppm of 5 to 100; Sodium, ppm of 10 to 500; Gravity, API of 1.0 to 16.0; Viscosity (cST), 122°F. of 100 to 5,000,000; Viscosity (cST), 210°F. of 10 to 16,000; LHV (BTU/LB) of 15,000 to 19,000; and Asphaltenes, wt. % of 5.0 to 25.0. Furthermore, according to the invention, the viscous crude hydrocarbon has a salt content, by weight with respect to the emulsion continuous phase, of less than or equal to about 1.0%, a total acid number of greater than or equal to about 1, preferably greater than or equal to about 2.5, an API gravity of less than 16 and a viscosity at ambient temperature of between about 10,000 cp to about 500,000 cp. The total acid number (TAN) refers to the volume, in cc's, of N/10 potassium hydroxide which are necessary to neutralize one gram of the viscous crude hydrocarbon. Thus, a TAN of 1 means that the hydrocarbon is such that 1 cc of N/10 KOH will neutralize one gram of the hydrocarbon. Most hydrocarbons in their natural state contain inactive potential surfactant materials. It is the object of the invention to extract these inactive surfactants from the hydrocarbon and activate the inactive surfactant so as to emulsify the viscous crude hydrocarbon in water and stabilize the emulsion. The emulsion so formed is then easily transportable to facilities for processing as desired. The inactive potential surfactants which are activated, according to the present invention, are acids which are saponifiable and which act as surfactants in their dehydrogenated form. Such acids may contain, for example, carboxylic acid groups and phenol groups. According to the invention, the potential surfactants are extracted and activated by a buffer additive which is added to the emulsion water to form a basic aqueous buffer solution. The basic nature of the solution is apparently necessary for the activation of the inactive surfactants, and the buffering helps to maintain the basic pH despite conditions to which the emulsion may be subjected which would normally cause the pH to fluctuate and which would, therefore, destabilize the emulsion. According to the invention, the buffer additive is preferably either sodium bicarbonate with sodium hydroxide, or sodium silicate. The function of the buffer additive is to raise the pH of the aqueous buffer solution to provide a basic aqueous buffer solution, to extract the inactive surfactants from the hydrocarbon, and to activate the surfactant by saponifying or dehydrogenating the inactive surfactant so as to provide an active natural surfactant for stabilizing the emulsion. According to the invention, the emulsion is formed as follows. Basic aqueous buffer solution is formed by adding the buffer additive to water at a concentration of equal to or greater than about 1,500 ppm, and preferably less than or equal to about 15,000 ppm. Preferably, buffer additive is added in amounts sufficient to provide a pH of the basic aqueous buffer solution between about 9 to about 11. The aqueous buffer solution is then mixed with the viscous crude hydrocarbon at a mixing rate sufficient to provide an emulsion of the hydrocarbon in the buffer solution having desired viscosity and droplet size characteristics. The hydrocarbon and buffer solution are preferably mixed at a ratio, by weight, of hydrocarbon to buffer solution of at least about 50:50, preferably 60:40 and more preferably 70:30. The mixing step is preferably carried out at a mixing rate of greater than or equal to about 800 rpm so as to provide an emulsion having viscosity at room temperature of less than or equal to about 2,000 cp, and having an average droplet diameter of greater than or equal to about 3 µm, preferably greater than or equal to about 50 µm. This droplet size makes it easier to break the emulsion which, as mentioned above, is desirable after the emulsion has been transported to treatment facilities. Such emulsions are typically broken so as to reform an emulsion according to more refined parameters for various end uses such as combustible fuels and the like. When the buffer additive is sodium bicarbonate, sodium hydroxide is added to the solution in amounts sufficient to provide the desired basic pH, preferably between about 9 to about 11 as described above. Sodium bicarbonate is added at the aforedescribed concentration of between about 1,500 ppm to about 15,000 ppm to buffer the basic solution and to provide the means for extracting and activating the inactive surfactant of the hydrocarbon when the emulsion is mixed. When the buffer additive is sodium silicate, the proper pH is provided by manipulating the molar ratio in the sodium silicate of Na 2 O to SiO 2 . Providing a molar ratio of Na 2 O to SiO 2 of greater than or equal to about 2.1 will provide a pH of the buffer solution of between about 9 to about 11 when the buffer additive is provided at a concentration in the solution of between about 1,500 ppm to about 15,000 ppm. It should be noted that the emulsion of the present invention may be formed at any convenient and desirable location along the production path of the viscous crude hydrocarbon. It is known, for example, to form such emulsions downhole, or at the well head, or at collecting stations serving multiple wells. Naturally, due to the highly viscous nature of the hydrocarbon, it is preferable to form the emulsion as soon as possible so as to take maximum advantage of the improved viscosity of the emulsion. According to a preferred embodiment of the invention, bimodal emulsions may be formed having further improved viscosity characteristics. A bimodal emulsion is an emulsion where the droplets of the dispersed phase have two distinct average droplet diameter populations. It has been found that such an emulsion can be provided, according to the invention, by utilizing a concentration of buffer additive in the aqueous buffer solution of at least about 8,000 ppm. Such a bimodal emulsion preferably has a small droplet size population having an average droplet size of up to about 4 microns, and a large droplet size population having an average droplet size of between about 4 microns to about 20 microns. As demonstrated in the examples below, such a bimodal emulsion has significantly improved viscosity characteristics as compared to a monomodal emulsion having a single average droplet size corresponding to the average droplet size of the bimodal emulsion. Emulsion formed according to the invention is easily transportable due to the reduced viscosity of the emulsion and is provided without the cost of commercial emulsifiers. According to the invention, such an emulsion may preferably be transported as follows. In a conventional pipeline system, the emulsion is preferably preceded and followed by a plug of additional basic aqueous buffer solution which may be provided in the same manner as the basic aqueous buffer solution of the emulsion, or which may be any other conveniently provided basic aqueous buffer solution. It is noted, for example, that it is not necessary to use the buffer additive of the present invention in formulating the plugs of additional basic aqueous buffer solution since the plugs are not to be emulsified with the hydrocarbon and therefore do not need to extract and activate the natural inactive surfactants contained therein. Thus, any convenient additive may be used to provide the additional basic aqueous buffer solution. According to the invention, a first volume or plug of the additional basic aqueous buffer solution is pumped through the pipeline, which is followed by the emulsion to be transported, which is in turn followed by a second volume or plug of the additional basic aqueous buffer solution. Preferably, the first and second volumes of additional basic aqueous buffer solution are equal to the volume of a length of about 4.0 km of the pipeline through which the emulsion is to be transported. Example 1 This example demonstrates the relation between mixing rate and stability of the emulsion formed according to the present invention. A Zuata crude was provided having the following characteristics: Density at 15°C, 1.005 kg/l; API gravity at 60°F, 9.3; kinetic viscosity at 100°F, 11,936 cST; kinetic viscosity at 140°F, 1,654 cST; and Sulphur content, % M/M, of 3.35. Buffer additive was used at a concentration of 10,000 ppm. Emulsions were prepared at a ratio by weight of hydrocarbon to buffer solution of 60:40. These emulsions were prepared at varying mixing rates, and the droplet diameter of the emulsions formed was monitored over time. Tables 1 and 2 below present the data obtained for emulsions prepared with sodium hydroxide/sodium bicarbonate and with sodium silicate, respectively. Days 600 RPM 800 RPM 1,000 RPM 1,300 RPM µm µm µm µm 1 83 54 48 35 3 95 60 47 40 5 >100 62 49 40 7 Big Flocs 63 50 42 9 60 48 39 Table 1 shows that emulsions formed using sodium hydroxide and 10,000 ppm sodium bicarbonate were stable when mixed at 800 rpm or higher. Emulsion formed at 600 rpm was unstable. Days 600 RPM 800 RPM 1,000 RPM 1,300 RPM µm µm µm µm 1 100 100 85 78 3 100 100 98 83 5 Flocs 100 100 85 7 100 100 81 9 100 100 89 Table 2 indicates, similar to Table 1, that 10,000 ppm sodium silicate provides stable emulsions at 800 rpm and higher. Example 2 This example demonstrates the relation between buffer additive concentration and emulsion stability. Emulsions were formed using varying concentrations of sodium silicate and using the same crude as in Example 1, at a ratio of crude to buffer solution of 60:40. The emulsions were mixed at 800 rpm, and viscosity was measured over time. Table 3 below contains the data so obtained. Buffer Concentration Viscosity Stability PPM MPA-SEC Days 1,000 unmeasurable 0.13 1,300 78 0.83 1,500 73 >6 1,650 72 >6 1,800 90 >6 2,000 94 >6 As shown, emulsions formed using less than 1,500 ppm buffer additive were very unstable and broke within a 24 hour period. At 1,500 ppm and higher, emulsions were provided which were stable for at least 6 days. Example 3 Emulsions were formed as in Example 2, having ratios of crude to buffer solution of 60:40 and 70:30, at varying concentrations of sodium silicate. Both viscosity and average droplet diameter were monitored. Tables 4 and 5 below contain data obtained at ratios of 60:40 and 70:30 respectively. RATIO - 60:40 Buffer Concentration Viscosity Average Droplet Diameter PPM MPA-SEC µm 2,000 38.55 67.08 4,000 47.12 25.89 6,000 169.6 6.76 8,000 292.4 2.95 10,000 125.4 2.28 RATIO - 70:30 Buffer Concentration Viscosity Average Droplet Diameter PPM MPA-SEC µm 2,000 324.2 48.12 4,000 574.2 8.47 6,000 1236 2.75 8,000 1341 1.03 10,000 762.2 1.11 At both ratios, average droplet diameter decreased as the concentration of buffer additive was increased. Further, up to 8,000 ppm, viscosity increased as the concentration of buffer additive was increased. Above 8,000 ppm, however, emulsions having both ratios indicated a decrease in viscosity. It was found that this decrease in viscosity was apparently caused by the formation of two distinct populations of droplets having different average droplet diameters, that is, bimodal emulsions were formed. Fig. 1 and 2 show the distribution of droplet size of the emulsion, the two distinct populations being indicated by the separate spikes or humps in the distribution. Example 4 This example demonstrates the stability of emulsions, formed according to the invention, during transport. An emulsion was formed as in Example 1, using Zuata crude in buffer solution at a ratio of 60:40. The buffer additive was sodium silicate at a concentration of 1,600 ppm, the emulsion being mixed in a reciprocal pump. A pipeline having a length of 55 km and a diameter of 6 inches was provided and equipped with temperature and pressure sensors along its length which were linked to a computer to gather data. The emulsion was pumped back and forth along the pipeline for 16 days, each time being preceded and followed by a plug of buffer solution equal to about 4 km of the pipeline. The emulsion was pumped at different flow rates and the pressure monitored. Significant changes in pressure would indicate meaningful changes in viscosity. The data so obtained is set forth in Table 6. Time Flow Rate Pressure Days Barrels per Day PSI 1 7,424 880 2 7,118 860 3 5,228 530 4 5,528 540 5 7,278 6 6,435 7 6,336 8 6,512 560 9 600 10 5,490 600 11 12 5,217 390 13 5,140 14 5,143 560 15 640 16 600 As shown, flowing the emulsion at rates of between about 5,000 to about 7,000 barrels per day for 16 days caused no significant variations in pumping pressure and, therefore, indicate a highly transportable emulsion. Example 5 This example further demonstrates the stability of emulsions of the present invention during transport and also during storage. An emulsion was prepared as described in Example 4 above. The emulsion was pumped through a 55 km pipeline, having a 6 inch diameter, between station San Diego and station Budare. 1,440 m 3 of emulsion were preceded and followed in the pipeline by 4 km plugs of additional basic aqueous buffer solution. The emulsion was transported 3 times along the length of the pipeline, for a total of 165 km. The emulsion was tested every 2 hours during transportation. Oil to water ratio, droplet size, viscosity and pressure were measured. The results are shown in Figs. 3 and 4. No significant variation was observed. The increased pressure in the Budare - San Diego leg was due to an increase in flow rate, and the pressure increase in the final leg of the transport was caused by a change in droplet size due to passing the emulsion through two reciprocating pumps, in series, located along the pipeline. After transportation, the emulsion was stored in a 1,590 m 3 tank for a period of 30 days. Samples of the emulsion were taken periodically from the top and the bottom of the tank and measured for droplet size, viscosity, and oil to water ratio. Figures 5 and 6 reflect the data so obtained for the tank bottom and top respectively. As shown, the emulsion remained substantially unchanged in the tank for the period of 30 days, indicating an excellent stability. The preceding examples indicate that emulsions formed according to the present invention, without commercial emulsifiers, provide an excellent vehicle for the transport of viscous crude hydrocarbons. Such emulsions are stable and have reduced viscosity greatly facilitating transport.

Claims: A method for forming a stable emulsion of a viscous crude hydrocarbon in an aqueous buffer solution, comprising the steps of: providing a viscous crude hydrocarbon containing an inactive natural surfactant and having a salt content by weight of less than or equal to about 1.0% and having a total acid number of greater than or equal to about 1; forming a solution of a buffer additive in an aqueous solution to provide a basic aqueous buffer solution, the buffer additive being operative to extract and activate the inactive natural surfactant from the viscous crude hydrocarbon and selected from the group consisting of (a) sodium hydroxide with sodium bicarbonate and (b) sodium silicate; and mixing the viscous crude hydrocarbon with the aqueous buffer solution at a rate sufficient to provide an emulsion of the viscous crude hydrocarbon in the aqueous buffer solution, whereby the buffer additive extracts the inactive natural surfactant from the viscous crude hydrocarbon and activates the inactive natural surfactant so as to stabilize the emulsion. A method according to claim 1, wherein the step of providing a viscous hydrocarbon includes providing a viscous hydrocarbon having a total acid number of greater than or equal to about 2.5. A method according to claim 1, wherein the aqueous buffer solution has a pH of between about 9 to about 11. A method according to claim 1, wherein the step of providing a viscous crude hydrocarbon includes providing a viscous crude hydrocarbon having an API gravity of less than or equal to about 16 degrees, and a viscosity at ambient temperature of between about 10,000 cp to about 500,000 cp. A method according to claim 1, wherein the inactive natural surfactant comprises at least one saponifiable acid. A method according to claim 1, wherein the buffer additive is mixed in the aqueous solution at a concentration of between about 1,500 ppm to about 15,000 ppm. A method according to claim 6, wherein the buffer additive is mixed in the aqueous solution at a concentration of at least about 8,000 ppm, whereby the step of mixing the viscous crude hydrocarbon with the aqueous buffer solution provides a stable viscous crude hydrocarbon-in-aqueous buffer solution emulsion having two distinct average droplet diameter populations. A method according to claim 7, wherein the step of mixing buffer additive at a concentration of at lease about 8,000 ppm provides a stable viscous crude hydrocarbon-in-aqueous buffer solution emulsion having a first distinct average droplet diameter population of up to about 4 µm and a second distinct average droplet diameter population of between about 4 µm to about 20 µm. A method according to claim 1, wherein the buffer additive is sodium hydroxide with sodium bicarbonate, the method further including the steps of mixing the sodium hydroxide in an amount sufficient to provide a pH of the aqueous buffer solution of between about 9 to about 11, and mixing the sodium bicarbonate at a concentration in the aqueous buffer solution of between about 1,500 ppm to about 15,000 ppm. A method according to claim 1, wherein the buffer additive is sodium silicate, the method further including the steps of mixing the sodium silicate at a concentration in the aqueous buffer solution of between about 1,500 ppm to about 15,000 ppm, the sodium silicate being provided having a molar ratio of Na 2 O to SiO 2 of greater than or equal to about 2.1 so as to provide a pH of the aqueous buffer solution of between about 9 to about 11. A method according to claim 1, wherein the mixing step includes mixing the viscous crude hydrocarbon and the aqueous buffer solution at a rate equal to or greater than about 800 rpm so as to provide a stable emulsion having a viscosity of less than or equal to about 2000 cp at room temperature and having an average droplet diameter of greater than or equal to about 3µm. A method according to claim 11, wherein the mixing step includes mixing the viscous crude hydrocarbon with the aqueous buffer solution so as to provide an emulsion having an average droplet diameter of greater than or equal to about 50 µm. A method according to claim 1, wherein the mixing step includes mixing the viscous crude hydrocarbon and the aqueous buffer solution at a ratio by weight of viscous crude hydrocarbon to aqueous buffer solution of greater than or equal to about 50:50. A method according to claim 13, wherein the ratio is greater than or equal to about 60:40. A method according to claim 13, wherein the ratio is greater than or equal to about 70:30. A viscous crude hydrocarbon-in-aqueous buffer solution emulsion, comprising: a viscous crude hydrocarbon discontinuous phase having a salt content by weight of less than or equal to about 1.0% and having a total acid number of greater than or equal to about 1; and a basic aqueous buffer solution continuous phase containing a buffer additive selected from the group consisting of (a) sodium hydroxide with sodium bicarbonate and (b) sodium silicate and a natural surfactant, the natural surfactant being an inactive surfactant naturally contained in the viscous crude hydrocarbon which inactive surfactant is extracted and activated by the buffer additive so as to stabilize the viscous crude hydrocarbon-in-aqueous buffer solution emulsion. An emulsion according to claim 16, wherein the total acid number is greater than or equal to about 2.5. An emulsion according to claim 16, wherein the basic aqueous buffer solution continuous phase has a pH of between about 9 to about 11. An emulsion according to claim 16, wherein the viscous crude hydrocarbon has an API gravity of less than or equal to about 16 degrees, and a viscosity at ambient temperature of between about 10,000 cp to about 500,000 cp. An emulsion according to claim 16, wherein the inactive surfactant is at least one saponifiable acid which is active with the buffer additive to form the natural surfactant. An emulsion according to claim 16, wherein the buffer additive has a concentration in the aqueous buffer solution of between about 1,500 ppm to about 15,000 ppm. An emulsion according to claim 21, wherein the buffer additive has a concentration in the aqueous buffer solution of greater than or equal to about 8,000 ppm, and the emulsion is characterized by two distinct droplet size populations. An emulsion according to claim 16, wherein the buffer additive is sodium hydroxide with sodium bicarbonate, the sodium hydroxide providing a pH of the aqueous buffer solution of between about 9 to about 11 and the sodium bicarbonate having a concentration in the aqueous buffer solution of between about 1,500 ppm to about 15,000 ppm. An emulsion according to claim 16, wherein the buffer additive is sodium silicate, the sodium silicate having a molar ratio of Na 2 O to SiO 2 of greater than or equal to about 2.1 so as to provide the aqueous buffer solution with a pH of between about 9 to about 11, the sodium silicate having a concentration of between about 1,500 ppm to about 15,000 ppm. An emulsion according to claim 16, wherein the emulsion has a ratio by weight of viscous crude hydrocarbon to aqueous buffer solution of greater than or equal to about 50:50, a viscosity at room temperature of less than or equal to about 2000 cp, and an average droplet diameter of greater than or equal to about 3 µm. An emulsion according to claim 25, wherein the ratio is greater than or equal to about 60:40. An emulsion according to claim 25, wherein the ratio is greater than or equal to about 70:30. An emulsion according to claim 25, wherein the emulsion has an average droplet diameter of greater than or equal to about 50 µm. A method for transporting a viscous crude hydrocarbon-in-aqueous buffer solution emulsion in a pipeline, comprising the steps of: providing a viscous crude hydrocarbon-in-aqueous buffer solution emulsion comprising a viscous crude hydrocarbon discontinuous phase and a basic aqueous buffer solution continuous phase containing a buffer additive selected from the group consisting of (a) sodium hydroxide with sodium bicarbonate and (b) sodium silicate and a natural surfactant, the natural surfactant being an inactive surfactant naturally contained in the viscous crude hydrocarbon which inactive surfactant is extracted and activated by the buffer additive so as to stabilize the viscous crude hydrocarbon-in-aqueous buffer solution emulsion; flowing a first volume of a basic aqueous buffer solution through the pipeline; flowing the emulsion through the pipeline following the first volume of basic aqueous buffer solution; and flowing a second volume of a basic aqueous buffer solution through the pipeline following the emulsion. A method according to claim 29, wherein the first and second volumes of basic aqueous buffer solution are the same as the basic aqueous buffer solution used to form the emulsion. A method according to claim 29, wherein the steps of flowing the first and second volumes of basic aqueous buffer solution each include flowing a volume of basic aqueous buffer solution equal to a volume of a length of about 4 km of the pipeline.

Inventors: PADRON AARON, PADRON, AARON
Applicants: MARAVEN SA, MARAVEN S.A.
Application year: 1994
Main classification: F17D1
IPC codes: F17D1, B01F3, B01F17, C10L1, E21B43